Controlling Salmonella in Poultry Plants

1. 1 Controlling Salmonella in Poultry Plants For the FSIS �How to� Workshops Spring 2009 Presented by Dr. Patricia Curtis and Ms. Jessica Butler Auburn University

2. Objectives 2

3. Salmonella Rod-shaped, motile bacterium Non-spore forming Gram negative Found on animals and in the environment Grows well at body temperature 3

4. Salmonella (con�t) Optimum temperature for growth is between 35�C and 37�C Slow growth has been observed at 5�C, with a maximum growth between 45�C and 47�C Growth may occur between pH 4.0 (depending on the acid) and pH 9.0; optimum pH is between 6.5 and 7.5 D-value of 4 to 5 minutes at 60�C has been reported for Salmonella 4

5. Salmonella (con�t) Over 2,000 different Salmonella serotypes All serotypes are now being compared to the CDC list of top 30 75% of all �A� sets have fewer than four serotypes linked to CDC list 5

6. It is important to know which serotypes of Salmonella you have! 6

7. Top 30 Serotypes in 2005 7

8. Preharvest Salmonella Control 8

9. Preharvest Salmonella Control Restricting access Vehicles People Animals Biosecurity Dedicated clothing and boots Disinfectant boot dip 9

10. Preharvest Salmonella Control (con�t) Feed Heat treated Pelletized Litter Maintain low water activity 10

11. Recommended Preharvest Best Practices Implement biosecurity measures Use good sanitation practices Control litter moisture Use well-timed feed withdrawal Use acids in drinking water during feed withdrawal 11

12. Discussion Questions What do you know about the live birds from which you are producing product? Do you know the level of Salmonella contamination? 12

13. 13 FSIS Category Levels for Serotypes Samples containing 1 of the top 30 serotypes identified by CDC Low level 0�1 samples per set Medium level 2�4 samples per set High level Greater than 5 samples per set

14. Target for Salmonella Reduction 14

15. 15 Salmonella and HACCP Plans A poultry HACCP plan MUST have a critical control point (CCP) to address Salmonella Support documentation is required Verification of the HACCP plan�s ability to control Salmonella is required

16. Sanitation What role does sanitation play in controlling Salmonella? 16

17. Sanitation (con�t) Plants may address Salmonella control in their sanitation standard operating procedure (SOP) or other prerequisite program How effective is YOUR sanitation program in controlling Salmonella? 17

18. Sanitation and Hygiene Clean before sanitizing Enforce employee hygiene 18

19. Sanitation and Hygiene (con�t) Alkaline Detergents Sodium hydroxide Nitrous oxide Sodium silicate Trisodium phosphate Note: Frequently used and vary in strength Acid Detergents Hydrochloric acid Sulfuric acid Phosphoric acid Acetic acid Note: Vary in strength 19

20. Sanitation and Hygiene (con�t) Sanitizers Quaternary ammonia* Industrial strength bleach Iodine compounds Peracetic acid Steam Ozone Some sanitizers work better in certain parts of the plant Iodophors Aluminum equipment, rubber belts, tile walls Active chlorine Walls (other than tile), wooden crates, concrete floors 20

21. Live Receiving and Live Hanging Recommended best practices Sanitize and dry cages thoroughly Maintain positive air flow from inside to outside the plant Provide SOP and employee training Schedule flocks for slaughter based on pathogen loads 21

22. Stunning and Bleeding Recommended best practices Consider electrical stunning Cheapest and most effective method Use well-timed feed withdrawal to reduce feces release 22

23. Scalding Recommended best practices Use counter-flow water movement Use high flow rates with agitation to help dilute dry matter and bacteria Use multi-stage tanks Maintain pH above 7.5 or below 6.5 Use pre-scald brushes to help clean birds before entering scalder Use post-scald rinse to help remove debris Maintain scalder temperature 23

24. Picking Recommended best practices Prevent feather buildup on equipment Rinse equipment and carcasses Use 18�30 ppm chlorine rinse post-picking 24

25. Evisceration Recommended best practices Adjust and maintain equipment regularly and as needed Use 20 ppm chlorine for whole-carcass rinses Enforce employee hygiene standards 25

26. Evisceration (con�t) Carcass rinses 23 ppm free available chlorine 10% TSP (trisodium phosphate) 2% lactic acid 5% sodium bisulfate 5% cetylpyridinium chloride Be aware how chemical residues can impact pH of chiller 26

27. Immersion Chilling If using chlorine, maintain chill water at pH between 6.0 and 6.5 and at a temperature of less than 40�F Use high water flow rate and counter-current flow Use 20�50 ppm free available chlorine in the potable water measured at intake Use oxidation reduction potential pH with pH monitors 27

28. Immersion Chilling (con�t) 10 ppm free available chlorine can eliminate Salmonella in 120 minutes 30 ppm free available chlorine can eliminate Salmonella in 6 minutes 50 ppm free available chlorine can eliminate Salmonella from the water in 3 minutes Note: Organic matter in the chiller binds the free chlorine and thus makes it unavailable. 28

29. Factors Affecting Chiller Water Quality High flow rate (1 gallon per bird) Counter-current water flow 20�50 ppm free available chlorine measured at intake Red water (recycled water) may contain up to 5 ppm free available chlorine measured at intake Water pH 6.0�6.5 Water temperature less than 40�F 29

30. Air Chilling Meet regulatory requirements for chilling Clean and oil chains regularly Inspect and replace shackles as needed Maintain tension on chain to prevent carcass-to-carcass contact Sanitation is important�no chemical interventions 30

31. Reprocessing Use post-chill antimicrobial dips to reduce Salmonella loads Heated water, agitation, application under pressure, and calibrating pH can enhance Salmonella reduction 31

32. Reprocessing: Approved Substances Chlorine, chlorine dioxide, and acidified sodium chlorite Water soluble Spray or dip Agitation and application under pressure enhance effectiveness 32

33. Reprocessing: Approved Substances (con�t) Chlorine Primarily used to treat processing and chiller water Heat and pH above 6.5 decrease its effectiveness Chlorine dioxide Can be used in water Leaves no residue Should NOT exceed 3 ppm residual chlorine dioxide 33

34. Reprocessing: Approved Substances (con�t) Acidified sodium chlorite Combination of citric acid and sodium chlorite Can be used as spray or dip at 500 to 1,200 ppm singly or in combination with other generally recognized as safe (GRAS) acids to achieve a pH between 2.3 and 2.9 as an automated reprocessing method In chiller water, it is limited to 50 to 150 ppm singly or in combination with other acids to achieve a pH between 2.8 and 3.2 34

35. Reprocessing: Approved Substances (con�t) Trisodium phosphate (TSP) Approved for on-line reprocessing Acts as a surfactant (high pH) Residual TSP carries over into chiller Must monitor pH of chiller water Rinsing carcasses after TSP but prior to chiller decreases its effectiveness More effective with air chilling than with immersion chilling 35

36. Reprocessing: Approved Substances (con�t) Cetylpyridinium chloride Quaternary ammonium compound Approved for processing in ready-to-cook poultry products Produces no adverse organoleptic effects pH is near neutral Stable, non-volatile, and soluble in water 36

37. Reprocessing: Approved Substances (con�t) Inspexx 100 Peroxyacetic acid Approved as a carcass spray for OLR Must not exceed 220 ppm Spectrum Peroxyacetic acid and a proprietary substance Can be used in process, scalder, and chiller water and as a carcass spray, wash, or dip 37

38. Reprocessing: Approved Substances (con�t) Other organic acids Lactic acid Most commonly used organic acid Applied as rinse Has an organoleptic effect on raw product Acetic acid Decreases pH and enhances the washing effect of scalder tank water Has an organoleptic effect on raw product 38

39. Web Sites for Most Currently Approved Substances Safe and Suitable Ingredients Used in the Production of Meat and Poultry Products http://www.fsis.usda.gov/OPPDE/rdad/FSISDirectives/7120.1Amend13.pdf Proprietary Substances http://www.fsis.usda.gov/Frame/FrameRedirect.asp?main=http://www.fsis.usda.gov/OPPDE/larc/ProprietarySubstances.htm 39

40. Further Processing To prevent cross-contamination: Sanitize well Practice good hygiene Keep poultry meat below 40�F Consider air flow and traffic patterns 40

41. Plant Variation Russell, Scott 2006

42. Validation 9 CFR 417.4 Validation verifies the effectiveness of interventions Establishments must validate their intervention processes 42

43. Acceptable Validation Methodologies Scientific articles Process mapping Validation study 43

44. Summary Salmonella continues to be an issue in poultry processing plants Each plant is unique and must determine the best way to control Salmonella in their operation Bio-mapping provides a way to identify critical areas where control measures should be applied 44

45. Summary (con�t) Multiple hurdles are better at controlling Salmonella than single control measures Salmonella testing should be done on a regular basis to validate control measures are working Sanitation effectiveness should be monitored 45

46. Salmonella Summary Optimum temperature for growth is between 35�C and 37�C Slow growth has been observed at 5�C, with a maximum growth temperature between 45�C and 47�C Growth may occur between pH 4.0 (depending on the acid) and pH 9.0; optimum pH is between 6.5 and 7.5 D-value of 4 to 5 minutes at 60�C has been reported for Salmonella 46